Efficient electrocatalytic nitrate reduction using 3D copper foam-supported Co hexagonal nanoparticles in a membrane electrode assembly

Electrocatalytic nitrate reduction reaction (NO3RR) provides a promising route for nitrate recycling and ammonia production. In this work, Co nanoparticle catalyst was developed on a copper foam substrate (CoNPs/CF) by electrodeposition. The CoNPs/CF catalysis exhibits a Faradaic efficiency (FE) of 92.0% at −0.2 V vs. RHE and an NH3 yield rate of 14328.65 μg h−1 cm−2 at −0.5 V vs. RHE. In-suit Raman spectroscopy and theoretical calculations demonstrated that the 3D copper foam structure of the substrate enhances the electron exchange capacity, which promotes the adsorption of nitrate on the cobalt (Co) surface. Moreover, Membrane Electrode Assembly (MEA) is employed with CoNPs/CF, contributing to 98.43 mg h−1 with FE over 80%. Coupled with an air stripping process, this configuration has enabled the successful production of high-purity gaseous NH3 products. This work suggests a practical and viable approach for the conversion of wastewater nitrate into valuable ammonia products.